Devices and Methods for Automated Mobile BioDiesel Production

ABSTRACT

At least one exemplary embodiment is directed to a device that uses a co-axial oil and methoxide flow to near real time mix the two flows into biodiesel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of 60/744,848, 60/744,945,60/745,060, and 60/745,176, under 35 U.S.C. § 119(e), all of which areincorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The invention relates in general to devices and methods of for theautomation of biodiesel production and in particular, though notexclusively, for the mobile production of biodiesel.

BACKGROUND OF THE INVENTION

Biodiesel has several manual elements such as titration as part of theproduction process. Additionally the formation time can take up to 8hours.

The current method (FIG. 1A) of biodiesel production involves picking upF1 a feedstock oil (e.g. soybean oil, waste oil) delivering (FT1) thefeedstock oil to a storage facility (SF1), then to processing plant(PP1), then to a biodiesel storage tank (BD1), then shipping D1 (e.g.,via tanker trucks) the finished product (e.g., biodiesel) back to theregional areas to serve as fuel. A business method that would locallyprocess collected feedstock oil would significantly decreasetransportation costs involved with biodiesel production and improve theoverall efficiency of the market delivery.

SUMMARY OF THE INVENTION

At least one exemplary embodiment is directed to an automated titrationsystem.

At least one exemplary embodiment is directed to an automated methoxideprocess.

At least one exemplary embodiment is directed to a near real timebiodiesel production mixing process.

Further areas of applicability of exemplary embodiments of the presentinvention will become apparent from the detailed description providedhereinafter. It should be understood that the detailed description andspecific examples, while indicating exemplary embodiments of theinvention, are intended for purposes of illustration only and are notintended to limited the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will become apparent from thefollowing detailed description, taken in conjunction with the drawingsin which:

FIG. 1A illustrates the conventional business method of biodieselproduction and delivery;

FIG. 1B illustrates a business method of biodiesel production anddelivery in accordance with at least one exemplary embodiment;

FIG. 2 illustrates a mobile biodiesel production facility in accordancewith at least one exemplary embodiment;

FIG. 3 illustrates a mobile biodiesel production facility in accordancewith at least one exemplary embodiment;

FIG. 4 illustrates a mobile biodiesel production facility in accordancewith at least one exemplary embodiment;

FIG. 5 illustrates a schematic of an automated titration system inaccordance with at least one exemplary embodiment;

FIG. 6 illustrates an example of an automated titration device inaccordance with at least one exemplary embodiment;

FIG. 6 a illustrates a schematic of the steps of an automated titrationprocess in accordance with at least one exemplary embodiment;

FIG. 7 illustrates an example of a titration chamber in accordance withat least one exemplary embodiment;

FIG. 8 illustrates a schematic of an automated titration system inaccordance with at least one exemplary embodiment;

FIG. 9 illustrates an example of a sampling chamber and/or mixing deviceand/or methoxide production device in accordance with at least oneexemplary embodiment;

FIG. 10 illustrates an example of a sampling chamber and/or mixingdevice and/or methoxide production device in accordance with at leastone exemplary embodiment;

FIG. 11 illustrates a schematic of a mixing/separating system inaccordance with at least one exemplary embodiment; and

FIG. 12 illustrates a porous mixing system in accordance with at leaston exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE PRESENT INVENTION

The following description of exemplary embodiment(s) is merelyillustrative in nature and is in no way intended to limit the invention,its application, or uses.

Processes, methods, materials and devices known by one of ordinary skillin the relevant arts may not be discussed in detail but are intended tobe part of the enabling discussion where appropriate.

Additionally, the size of structures formed using the methods anddevices of exemplary embodiments are not limited by any discussionherein (e.g., the sizes of structures can be macro (centimeter, meter,size), micro (micro meter), nanometer size and smaller).

Additionally, examples of mixing/separating/sampling device(s) arediscussed, however exemplary embodiments are not limited to anyparticular device for mixing, separating, and sampling.

Additionally, other fluid besides those used in biodiesel production canbe used with the exemplary embodiments including gases.

FIG. 1A illustrates the conventional business method of biodieselproduction and delivery.

FIG. 1B illustrates a business method of biodiesel production anddelivery in accordance with at least one exemplary embodiment. In theembodiment illustrated a mobile processing plant PP2 (also referred toas processing centers) include devices to process feedstock oil intobiodiesel. Hence in this exemplary embodiment the processing plant PP2travels to the remote feedstock oil storage sites (e.g., Remote sites 1,2, and 3), processes the feedstock oil into biodiesel and stores thebiodiesel locally. This facilitates redistribution into the community.

FIG. 2 illustrates a mobile biodiesel production facility in accordancewith at least one exemplary embodiment. The feedstock oil storage 110pumps feedstock oil into the mobile processing plant 100. A sample ofthe feedstock oil is used in titration (e.g., 130 automatic titration)to determine the useful catalyst levels, e.g., from a catalyst device135). The useful level of catalyst is added to methanol 140 to formmethoxide, which is mixed with the feedstock oil in the mixing device150. The products from the mixing device includes a mixture whichincludes glycerin, unused feedstock oil, and biodiesel. The unusedportion of feedstock oil can be separated in a separating device 170,and recycled in a recycling loop 160 and injected back into the mixingdevice. The glycerine/waste can also be separated via the separatingdevice 170 and stored for later use 180. The separated biodiesel can bepumped into a biodiesel storage tank 120.

FIG. 3 illustrates a mobile biodiesel production facility in accordancewith at least one exemplary embodiment, where the glycerin is alsostored externally 180B and separately from the remaining waste 180A.

FIG. 4 illustrates a mobile biodiesel production facility in accordancewith at least one exemplary embodiment where water (for example storedexternally 190) can be used to purify the biodiesel prior to tankstorage. Additionally in place of an automated titration system a usercan enter titration parameters 130 A into a logic circuit that cancontrol the amount of catalyst used in the mixing device 150.

FIG. 5 illustrates a schematic of an automated titration system inaccordance with at least one exemplary embodiment, while FIG. 6illustrates an example of an automated titration device 130 inaccordance with at least one exemplary embodiment. Feedstock oil, whichcan be heated (e.g., via a heating circuit 525 as measured via atemperature gauge 527) can flow HO into sampling chamber 520 along withproducts from a titration chamber TC, a catalyst (e.g., ISO orIsopropyl), and some methanol via the catalyst chamber 550. Uponmeasurement of properties of the combined sample (e.g., PH meter 530) auseful level of catalyst 550 to add to methanol 590 can be determined toform methoxide 595 to add to the remaining feedstock flow HO1 in themixing device 570.

FIG. 6 a illustrates a schematic of the steps of an automated titrationprocess in accordance with at least one exemplary embodiment, where avalue of K is used to determine the difference between good feedstockoil (less contaminants), and poor feedstock oil, while determining thecatalyst level.

FIG. 7 illustrates an example of a titration chamber in accordance withat least one exemplary embodiment, where an automatic precision feedsystem 135 injects various levels of measured catalyst 565 b into atitration solution 565 a. In this exemplary embodiment the flow from thetitration solution chamber TC is injected into the sampling chamber 520.

FIG. 8 illustrates a schematic of an automated titration system inaccordance with at least one exemplary embodiment and as can be seenillustrates the flow of TC into the sampling chamber 520.

FIG. 9 illustrates an example of a sampling chamber and/or mixing deviceand/or methoxide production device in accordance with at least oneexemplary embodiment. Flows HO, ISO and TC can be injected into thesampling chamber 900, where parallel feed tubes and/or holes 910 b, 920b, and 930 c can more uniformly inject the flows. Optionally mixing arms940 a, attached to a rotatable mixing shaft 940 b (e.g., controlled by amixing control unit 940). The characteristics of the resultant mixedsample can be measured (e.g., via PH meter 950).

FIG. 10 illustrates an example of a sampling chamber and/or mixingdevice and/or methoxide production device in accordance with at leastone exemplary embodiment. In the exemplary embodiment a co-axial flow offeedstock oil (e.g., HO1) and Methoxide (e.g., MO1) can be set up toincrease interaction area. Optionally the co-axial flows can be impingedupon one or more mixing grids (e.g., 1050, 1060). The co-axial flows(e.g., 1030 c and 1030 b) can interact at their interface formingbiodiesel, and can additionally break up into aphronated droplets. Theco-axial flows can be used to maximize interface area. The cross-sectionof which can be varied to obtain a near zero relative velocity or arelative velocity to maximize mixing.

FIG. 11 illustrates a schematic of a mixing/separating system inaccordance with at least one exemplary embodiment and illustrates inblock form the relationship between the mixing device 1140 and it'sinputs and the separation device 1170 and it's exports.

FIG. 12 illustrates a porous mixing system in accordance with at leaston exemplary embodiment. Instead of using co-axial mixing flows anothermethod in accordance with at least one exemplary embodiment is to have aporous block (e.g., lava stone) that saturates the block 1200 withmethoxide (e.g., MCM). Channels (e.g., feedstock mixing channel 1210)can be drilled or otherwise formed (e.g., molding) into the block 1200allowing feedstock oil to pass through. The channel wall being porousallows MCM to seep in at the channel walls interacting with thefeedstock oil. A smaller channel will increase the % of penetrationdepth in the transverse direction (perpendicular to the channel axis).Thus channel lengths and widths, flow rates and pressure, can betailored to derive a % mixing along a standard length (e.g., 10 cm).

Centrifugal Separator

At least one exemplary embodiment is directed to a biodiesel processorsystem including a mixing region, spin separating region, and a flowseparating region, with optional recycling loops feeding back into thesystem. Note that if a feedback system is used then in at least oneexemplary embodiment titration is not used to determine the appropriateamount of catalyst. Instead an amount is assumed to correspond to pooroil, combined to form methoxide, and then recycled through the systemthrough the waste tubes until used.

The spin separator system can be cylindrical or slightly expanding (tohave a velocity component along the wall driving the fluid forwardaxially). As it spins the portions with a higher specific gravity willtend toward the walls while the lower specific gravities will accumulatetoward the central portions of the flow. For example if the entire spinseparator region if filled with mixed biodiesel, methanol, methoxide,waste, then the parts will separate as they start to spin inside therotating cylinder (Note, internal fins can be provided to aid thespinning). As the flow travels down the fluid portions start to separateaxially. When a useable amount has been separated, e.g. determined bysimple experiments, (for example the first 3 mm near the wall are 95%glycerin, 10 cm along the spin axis) then co-axial bleed tubes (flowseparator system) can take those portions of the flow out of therecycling flow and further purified if needed (e.g., the axial spinwater washing system illustrated in FIG. 3, where a similar spin systemas the spin separator system can be used with initial grid walls tocollect particulates and contaminates, with optionally water deliveredaxially, which the spin will move toward the wall. Note the water can beinjected near the axial line toward the beginning of the spin and that'sit. Along the axial direction the water which was near the center willbe spun to the walls cleaning the biodiesel, which can be bled throughanother axial bleed tube, and the system can go through a feedbackloop).

Porous Mixing Device

FIG. 12 illustrates a porous mixing system in accordance with at leastone exemplary embodiment. The porous block 1200 can of course be anyshape. The material of the block is one that will absorb methanol and/ormethoxide and/or recycled fluids and catalyst so as to be present at thesurface of feedstock mixing channel 1210 passing through the porousblock. FIG. 12 illustrates four feedstock mixing channels (tubes) 1210,although any number and size can be drilled or fabricated. The feedstockoil passes through an interface containing sub-tubes which areconstructed to match at least some of the tubes drilled in the block.The sub-tubes (feedstock oil feed channels 1230) delivery the feedstockoil through the interface (1220 feedstock interface plate) into theblock. The feedstock oil has associated with it a pressure, that inaccordance with the methanol and/or methoxide and/or waste fluidpressures feeding the porous block reservoir can be varied.

The pressure of the fluid saturating the porous block can be varied tominimize feedstock absorption by the porous block while encouraging thefluid in the porous block lining the tube surface to enter the feedstockoil stream. Thus the fluid absorbed in the porous block can then enterthe feedstock oil stream, mix and reacts to produce a chemical product(e.g., biodiesel). The size of the block, tube diameters, porosity ofthe block, and pressures can be easily varied to maximize reaction.

Any non converted feedstock oil, catalyst, methanol, methoxide, and anyother fluid used in the process can be recycled in a feedback loop.

FIG. 12 illustrates an example of the external connection of a porousmixing system with other devices in a biodiesel processing facility inaccordance with at least one exemplary embodiment, in addition to afigure illustrating optional one way flow layers, and a figureillustrating the pressure relationships between various flows andreservoirs. The porous mixing system can be operatively connected to afluid separator, pumps, valves and other fluid support systems necessaryto deliver the feedstock oil, and vary the fluid flows.

FIG. 12 illustrates a close-up of a tube section passing through aporous block, where the pores contain Methanol and/or Methoxide and/orWaste (referred to as MMW or MMC). Note that the material of the porousblock can vary depending on the physical porosity needed and resistanceto the chemicals used. (e.g., fired clay, porous rock, and otherabsorbent chemical resistant materials as known by one of ordinary skillin the relevant arts and equivalents).

Additionally the exemplary embodiment can include a gear driven axialspin separator. In the non-limiting example a tube can be tight fittedthrough the hole of a couple of bearing rings. The tight fit can befluid tight but can also include a sealant at an interface. Theinterface can include a sub-tube that delivers a first fluid (feedstockoil (FO)) into the tight fitted tube. For the tube to rotate there is agap G between the plate and the tube (which has been tight fitted to thebearing ring). A seal on the plate can keep fluid from leaking radiallyalong the plate. Note also that the plate will have to have clearancewith respect to the inner portion of the bearing ring (the centerrotating part). Thus depending on how close the clearance is there canbe some fluid leakage. To minimize this the clearance is kept small anda positive pressure P* is exerted to aid in the surface tensionretention of the fluid in the rotating tube.

Additionally at least one exemplary embodiment can include amagnetically driven internal separator. An internally contained spinseparation system in accordance with at least one exemplary embodimentcan include, bearing rings which are contained within a fluid chamber(note that the bearings will need to be reasonable resistant to thereactants (BD, FO, Methanol, Methoxide, waste, and catalyst). In thenon-limiting example the outside surface of the rotating tube hasattached permanent magnets that can be influences by and externallyvarying magnetic field. The externally varying magnetic field can begenerated by an oscillating magnetic device M1, much like an electricgenerator is coerced to spin, except in this case there are no contactwires directly to the spinning portion, and the magnets reside on thespinning portion instead of the stationary portion.

Additionally, exemplary embodiments can include a cleansing unitcomprising, a first chamber, wherein the first chamber includesunprocessed biodiesel; a second chamber, wherein the first chamber isconnected to the second chamber via tubes; and a third chamber, whereinthe third chamber includes water that is cycled through the thirdchamber, wherein the third chamber lies between the first and secondchamber, wherein the tubes pass through the water of the third chamber,wherein the tubes are made of a material that facilitate the formationof an interface between the water and unprocessed biodiesel where watersoluble contaminants in the unprocessed biodiesel become at leastpartially removed and dissolved into the water, and where the biodieselentering the second chamber is processed in that at least a portion ofthe water soluble contaminants have been removed.

While the present invention has been described with reference toexemplary embodiments, it is to be understood that the invention is notlimited to the disclosed exemplary embodiments. The scope of thefollowing claims is to be accorded the broadest interpretation so as toencompass all such modifications and equivalent structures andfunctions.

1. A method of processing and delivering biofuels comprising: unloadingat least a first portion of a raw material in an at least one rawmaterial storage location into a mobile processing biofuels plant,wherein the mobile biofuels plant has been transported to a region nearthe raw material storage location; mixing the first portion with atleast one second portion of a mixing substance, wherein the mixing ofthe first and second portions creates a third portion of biofuel; andunloading from the mobile biofuels plant the third portion into abiofuels storage location, wherein the mobile biofuels plant can bemoved from the biofuels storage location after unloading the thirdportion.
 2. The method according to claim 1 wherein the mixing substanceis methanol.
 3. The method according to claim 2, further including asecond mixing substance that is also mixed with the first and secondportions.
 4. The method according to claim 3, wherein the mixing of themixing substance and the second mixing substance forms methoxide.
 5. Aspin separator comprising: a spinning chamber, wherein the spinningchamber has a spin axis; and a rotation support, wherein the rotationsupport is configured to spin the chamber at a predetermined rate thatis related to a selected separation portion along the spin axis, whereinthe spinning chamber separates flow inserted along the spin axis andexpelled along the spin axis, into axially separated portions inaccordance with their specific gravity.
 6. A flow separation systemcomprising: the spin separator according to claim 5; and at least twoco-axial tubes, a first tube and a second tube, configured to receive aportion of a first specific gravity fluid and a second specific gravityfluid respectively, wherein the first specific gravity and secondspecific gravity fluids are separated by the spin separator.
 7. Abiodiesel processing device comprising: an inner flow of feedstock oil;and an outer flow of methoxide, wherein the outer flow of methoxide is aco-axial sheath around the inner flow, and wherein the outer and innerflow at least partially mix forming a portion of biodiesel.
 8. Thebiodiesel processing device according to claim 7, wherein the inner andouter flow impinge upon a mixing grate.